EP3740157B1

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Info

Publication number: EP3740157B1
Application number: EP18913510.6A
Authority: EP
Inventors: Clifton Braun; Cody Badger; Karl Halden
Original assignee: Mueller International LLC
Current assignee: Mueller International LLC
Priority date: 2018-04-03
Filing date: 2018-11-30
Publication date: 2023-09-20
Anticipated expiration: 2038-11-30
Also published as: EP4223253B1; EP3740157A4; EP3740157A1; CA3092322A1; EP4286732A2; WO2019194870A1; US20200224811A1; EP4286732A3; US20190301657A1; US11221099B2; EP4286732B1; EP4549800A2; US10641427B2; EP4223253A1; EP4549800A3

Description

TECHNICAL FIELD

This disclosure relates to the field of pipe repair. More specifically, this disclosure relates to a stent for repairing a pipe.

BACKGROUND

Piping systems, including municipal water systems, can develop breaks in pipe walls that can cause leaking. Example of breaks in a pipe wall can include radial cracks, axial cracks, point crack, etc. Repairing a break in a pipe wall often requires the piping system to be shut off, which can be inconvenient for customers and costly for providers. Further, repairs can necessitate grandiose construction, including the digging up of streets, sidewalks, and the like, which can be costly and time-consuming.
US8783297B2 discloses a system for pipeline rehabilitation. The system includes repairing a leak in a pipe using a pair of substantially semi-cylindrical parts connected through a compliant j oint. When the parts are compressed, the semi-cylindrical parts form a cylinder whose outside diameter is less than the inside diameter of a pipe with a defect thereby allowing the cylinder to be inserted into the pipe at a location of a leak. Once in place, the parts engage the inside surface of the pipe when the compression is released thereby to seal the leak.
US5119862A discloses a pipe repair sleeve and liner with interlocking elements in a form of a coiled sheet which is covered with compressive gasket. An air bag is inserted into the coiled sleeve and moved to the location of the damaged pipe. Once in place, the air bag is inflated. As a result of the inflation, the repair sleeve uncoils and the surrounding gasket is compressed against the damaged pipe. When the air bag is deflated, the sleeve begins to coil and forces a male end of the sleeve into the female end forming a male and female interlocking continuous sleeve inside the pipe. After the repair sleeve is installed in the pipe, the air bag is removed from the sleeve.

SUMMARY

The invention is a stent for repairing a leak in a pipe carrying water, gas and/or oil as defined in independent claim 1 and a method for repairing a pipe as defined in independent claim 13. Preferred embodiments are set out in the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity.

FIG. 1 is an end view of a first aspect of a stent comprising a spring and a seal, according to the present disclosure, wherein the stent is in an expanded configuration.
FIG. 2 is an end view of the spring of the stent ofFIG. 1 in a compressed configuration.
FIG. 3 is a side view of the spring of the stent ofFIG. 1 in a rolled configuration.
FIG. 4 is a side view of the spring of the stent ofFIG. 1 in an unrolled configuration.
FIG. 5 is a perspective view of another aspect of the stent, according to the present disclosure, with the stent in the expanded configuration within a pipe.
FIG. 6 is a perspective view of the stent ofFIG. 5 in the expanded configuration within the pipe ofFIG. 5, the stent comprising a second sealing layer.
FIG. 7 is a perspective view of a spring of the stent ofFIG. 5 formed in a piece of sheet material.
FIG. 8 is a front view of the spring of the stent ofFIG. 5 in an unrolled configuration.
FIG. 9 is another aspect of a spring according to the present disclosure in an unrolled configuration.
FIG. 10 is an exploded view of another aspect of the stent according to the present disclosure.

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and the previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, and, as such, can, of course, vary, and the inventions is defined as in the appended claims.
It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
Figure 1 illustrates a first aspect of astent 100, according to the present invention. Thestent 100 comprises aspring 110 and asealing layer 130. Example aspects of thestent 100 can be expandable and compressible, such that thestent 100 can be oriented in an expandedconfiguration 102, as shown inFigure 1, and acompressed configuration 204, as shown inFigure 2. (Note that inFigure 2, thesealing layer 130 is removed for visibility of thespring 110.) According to example aspects, thestent 100 can be expanded within a pipe 550 (shown inFigure 5) such that thesealing layer 130 can engage aninner wall 552 of thepipe 550. In apipe 550 where a crack 554 (shown inFigure 5) or other damage is present, thesealing layer 130 can create a watertight seal between thestent 100 and the inner surface of thepipe 550 at the location of the damage to prevent leaking at the damage site.
As shown inFigure 1, thespring 110 biases thestent 100 to the expandedconfiguration 102. In the depicted aspect, thespring 110 is formed as atubular mesh structure 111 defining opposingopen ends 112a,b. Thespring 110 further defines an outer surface 314 (best seen inFigure 3) and an oppositeinner surface 116. Theinner surface 116 can define an inner diameter of thespring 110 and theouter surface 314 can define an outer diameter of thespring 110. Furthermore, theinner surface 116 defines avoid 120 extending between theopen ends 112a,b of thespring 110 and anaxis 122 extending through a center of thevoid 120. The opposingopen ends 112a,b of thespring 110 can allow for fluid flow through thevoid 120. Moreover, thespring 110 can define a spring force. In some aspects, thespring 110 can be formed from a plastic material, such as, for example, nylon, POM (polyoxymethylene), or PVC (polyvinyl chloride). In other aspects, thespring 110 can be formed from a metal material, such as stainless steel, spring steel, aluminum, nitinol, cobalt chromium, or any other suitable material. Optionally, the material can be an NSF certified material that can comply with various public health safety standards. For example, in some aspects, the material can be approved as safe for use in drinking-water applications. Furthermore, in some aspects, the spring can comprise a corrosion-resistant coating. In some aspects, instead of thespring 110, the stent can comprise a balloon for biasing thestent 100 from thecompressed configuration 204 to the expandedconfiguration 102, or any other suitable mechanism for expanding thestent 100.
In example aspects, thesealing layer 130 can be formed as a continuous,tubular sleeve structure 131 defining anouter surface 132 and aninner surface 134. Theinner surface 134 can define an inner diameter of thesealing layer 130, and theouter surface 132 can define an outer diameter of thesealing layer 130. The outer diameter of thesealing layer 130 can be defined as the diameter of the stent 100 (the "stent diameter"). Theinner surface 134 of thesealing layer 130 can engage theouter surface 314 of thespring 110. In some aspects, thesealing layer 130 can wrap around a circumference of thespring 110 and can cover the entireouter surface 314 of thespring 110, as shown. However, in other aspects, such as the aspect ofFigure 5, thesealing layer 130 can wrap around the circumference of thespring 110 and can cover only a portion of theouter surface 314 of thespring 110. In still other aspects, thesealing layer 130 does not wrap around the entire circumference of thespring 110.
Example aspects of thesealing layer 130 can comprise a flexible and compressible material, such as, for example, neoprene. In other aspects, thesealing layer 130 can be formed from another synthetic rubber material such as EPDM rubber, natural rubber, foam, epoxy, silicone, a resin-soaked cloth, or any other suitable flexible material for providing a watertight seat between thestent 100 and theinner wall 552 of the pipe 550 (pipe 550 shown inFigure 5). According to example aspects, the inner diameter of thesealing layer 130 can substantially match or be slightly smaller than the outer diameter of thespring 110, such that thesealing layer 130 can fit snugly on thespring 110. Thesealing layer 130 in some aspects can be coupled to thespring 110 by a fastener (not shown), such as, for example, stitching, adhesives, ties, or any other suitable fastener known in the art.
In the expandedconfiguration 102, as shown inFigure 1, the spring force can bias thespring 110 and thesealing layer 130 radially outward relative to theaxis 122, such that each of thespring 110 and sealinglayer 130 define the relatively tubular shapes, as shown. In the expandedconfiguration 102, thestent 100 can define its largest possible stent diameter. In thecompressed configuration 204, as shown inFigure 2, a compression force can be applied to theouter surface 132 of thesealing layer 130 by a compression mechanism (not shown). The compression force can overcome the spring force, and thesealing layer 130 andspring 110 can compress or fold radially inward towards the void 120 to define a smaller stent diameter and a smaller overall stent volume than in the expanded configuration 102 (shown inFigure 1). When the compression force is removed or reduced to less than the spring force, the spring force can bias thestent 100 back to the expandedconfiguration 102. In other aspects, instead of a compression force, a tension force (i.e., a pulling force) or any other suitable force can be applied thestent 100 to bias thestent 100 to thecompressed configuration 204.
An expansion ratio can be defined as the ratio between the stent diameter in the expandedconfiguration 102 and the stent diameter in thecompressed configuration 204. In example aspects, the expansion ratio can be between about 1.2/1 and 3/1. In other aspects, the expansion ratio can be between about 1.4/1 and 2.4/1. In still other aspects, the expansion ratio can be about 2/1. As will be described in further detail below, in thecompressed configuration 204, the reduced stent diameter can allow for easier insertion of thestent 100 into a pipeline (not shown) and easier navigation of thestent 100 through the pipeline.
Example aspects of thespring 110 can be oriented in a rolledconfiguration 140 for use, as shown inFigures 1-3, and an unrolledconfiguration 442, as shown inFigure 4. In example aspects, thespring 110 can be manufactured in the unrolledconfiguration 442, and rolled into the rolledconfiguration 140 thereafter for use. Referring toFigure 4, in the unrolledconfiguration 442, thespring 110 can be substantially flat and can define afirst end 444 and an opposingsecond end 446. Example aspects of thespring 110 can be rolled into the rolledconfiguration 140 from the unrolledconfiguration 442. Thefirst end 444 of thespring 110 can be coupled to thesecond end 446 to retain thespring 110 in the rolledconfiguration 140, as shown inFigure 3. According to example aspects, thefirst end 444 can be coupled to thesecond end 446 by a fastener, such as, for example, one or more nut andbolt assemblies 248, as best seen inFigure 2. In other aspects, the fastener can be adhesives, clips, snaps, ties, or any other suitable fastener or combination of fasteners know in the art.
Figure 5 illustrates thestent 100 according to another aspect of the disclosure, not part of the present invention, wherein thestent 100 is in the expandedconfiguration 102 within avoid 556 of thepipe 550. Thepipe 550 is illustrated as translucent for improved visibility of thestent 100. The void 556 can be defined by theinner wall 552 of the pipe. Like thestent 100 ofFigure 1, thestent 100 of the current aspect comprises thespring 110 and thesealing layer 130. In the present aspect, thespring 110 can be a wave-pattern spring 510. The wave-pattern spring 510 can comprise ametal wire 524 defining a wave pattern in the axial direction. Thespring 510 can be rolled into atubular structure 511 as shown. Thespring 510 in the rolledconfiguration 140 can define thevoid 120 and the axis 122 (shown inFigure 1) extending through thevoid 120. Example aspects of the void 120 can be concentric to thevoid 556 of thepipe 550. Thesealing layer 130 can form thesleeve 131 and can wrap around the circumference of thespring 510, engaging the outer surface 314 (shown inFigure 3) of thespring 510. As shown in the present aspect, portions of thespring 510 can extend beyond thesealing layer 130, such that thesealing layer 130 covers only a portion of theouter surface 314 of thespring 510. In other aspects, thesealing layer 130 can completely cover theouter surface 314 of thespring 510. In still other aspects, thesealing layer 130 may not extend around the entire circumference of thespring 510. In the present aspect, thesealing layer 130 is coupled to thespring 510 byzip ties 560. The zip ties 560 can be looped throughspring loops 526 formed on thespring 510 and can engage the material of thesealing layer 130 to secure thesealing layer 130 to thespring 510. In other aspects, however, a fastener other than the zip ties 560 can be used to attach thesealing layer 130 to thespring 510, such as, for example, sewing or an adhesive.
As shown, example aspects of thespring 510 can further comprise one ormore tabs 528 extending inward towards thevoid 120. Each of thetabs 528 can define an opening therethrough. In example aspects, a cable (not shown) can pass through the opening of each of thetabs 528 and can be tightened to contract thestent 100 to the compressed configuration through tension in the cable. The cable can be cut to release the contracting force on thestent 100 and to allow thespring 510 to bias thestent 100 to the expandedconfiguration 102. In other aspects, thestent 100 can be compressed by another compression or contraction mechanism, such as a compression sleeve, a dissolvable wire, or any other suitable mechanisms known in the art. In an aspect comprising a dissolvable wire, the wire can be dissolved by electricity, chemicals, water, or any other suitable dissolving mechanism. In still another aspect, the compression mechanism can be a hose clamp. In some aspects, the hose clamp or other compression mechanism can comprise a worm drive.
With thestent 100 in the expandedconfiguration 102 within thepipe 550, theouter surface 132 of the sealing layer 130 (shown inFigure 1) can press against theinner wall 552 of thepipe 550 to retain thestent 100 in position relative thepipe 550. Furthermore, thesealing layer 130 can press against acrack 554 in thepipe 550, or other damage to thepipe 550, to seal thecrack 554 and prevent leakage at thecrack 554.
Figure 6 illustrates thestent 100 ofFigure 5 with asecondary sealing layer 630. Thesecondary sealing layer 630 can be formed from the same material as thesealing layer 130, or can be formed from a different material. For example, in one aspect, thesealing layer 130 can be formed from neoprene and thesecondary sealing layer 630 can be formed from an epoxy. Other aspects of thesealing layer 130 andsecondary sealing layer 630 can be formed from other materials. In example aspects, thesecondary sealing layer 630 can be provided for improved sealing capability at the site of thecrack 554 or other damage. For example, thesealing layer 130 can serve as a general sealing solution and can provide support to thesecondary sealing layer 630, while thesecondary sealing layer 630 can serve as a more acute sealing solution. In some example aspects, thesecondary sealing layer 630 can comprise a compliant material that can be pressed into thecrack 554 or other damage. Furthermore, in some aspects, thesealing layer 130 can comprise a less compliant material configured to provide structure to the stent and support to the secondary sealing layer.
An example aspect of a method for using thestent 100 is also disclosed. A compression force (or contraction force in some instances) can be applied to thestent 100 to orient thestent 100 in thecompressed configuration 204, wherein thestent 100 has a reduced stent diameter as compared to the stent diameter in the expandedconfiguration 102. In one aspect, the compression force can be applied by a compression sleeve (not shown) having a smaller diameter than the stent diameter in the expandedconfiguration 102. In other aspects, the compression force can be applied by cables, ties, or another suitable compression mechanism.
In thecompressed configuration 204, the reduced stent diameter and reduced stent volume can allow for easy insertion of thestent 100 into the pipeline (not shown) and navigation through the pipeline. The pipeline can comprise one or more pipes, such as thepipe 550 shown inFigure 5. According to example aspects, the pipeline can transport a fluid along the pipeline, such as, for example, water, oil, or natural gas. Thestent 100 can be inserted into the pipeline in thecompressed configuration 204 at an existing access point. In an example aspect, the existing access point can be a fire hydrant. In other aspects, the existing access point can be the entrance or exit of the pipeline, a service entrance, or another suitable point of entry that allows for easy insertion of thestent 100 into the pipeline.
Once inserted into the pipeline, thestent 100 can be mechanically driven or motor-driven through the pipeline to the location of thecrack 554 or other damage. In instances where thestent 100 is moving through the pipeline in the direction of the fluid flow, a current of the fluid can assist in moving thestent 100 through the pipeline. As thestent 100 moves through the pipeline, fluid in the pipeline can continue to flow around and/or through thecompressed stent 100. As such, the flow of fluid in the pipeline can continue uninterrupted as thestent 100 is navigated through the pipeline. Such a configuration prevents the need to shut off the fluid flow during repairs, which can save costs for the service provider and prevent interruption of service to customers. Furthermore, inserting thestent 100 into the pipeline at an existing access point and remotely navigating thestent 100 through the pipeline can eliminate the need to dig up the surrounding terrain to access the damaged pipe, which can save time and costs when performing repairs.
Thecompressed stent 100 can be positioned in the pipeline proximate to thecrack 554 in thepipe 550. The compression force applied to thestent 100 by the compression sleeve, or other compression mechanism, can be removed or reduced, such that the spring force can bias thestent 100 to the expandedconfiguration 102. In the expandedconfiguration 102, theouter surface 132 of thesealing layer 130 of thestent 100 can contact theinner wall 552 of thepipe 550 and can press against thecrack 554 to create a watertight seal and prevent leakage at the crack location. In some aspects, a portion of thesealing layer 130 can be pushed into thecrack 554 for an improved seal. In example aspects, fluid pressure from the fluid flow in the pipeline can also assist in biasing thestent 100 against theinner wall 552 of thepipe 550.
With thestent 100 positioned in thepipe 550 in the expandedconfiguration 102, fluid in the pipeline can flow through the void 120 in thestent 100. Example aspects of thestent 100 can be sized and shaped to fit tightly in the pipeline in the expandedconfiguration 102. For example, in one aspect, the stent diameter in the fully expandedconfiguration 102 can be slightly greater than a diameter of theinner wall 552 of thepipe 550. The tight fit of thestent 100 within thepipe 550, along with fluid pressure against thestent 100, can aid in retaining thestent 100 in position at the location of thecrack 554 or other damage. In some aspects, thestent 100 in the expandedconfiguration 102 can also serve to add structural integrity to thepipe 550. In such aspects, thestent 100 can be formed from materials of a sufficient strength and can be provided with a sufficient spring force for providing structural support to thepipe 550 at the location of thestent 100. Some aspects of thestent 100 further can include a fastener for attaching thestent 100 to theinner wall 552 of thepipe 550, such as, for example, an adhesive. However, in other aspects, any other suitable fastener known in the art can be used to attach thestent 100 to thepipe 550.
Example aspects of thespring 110 can be cut from asheet 770 of material. Referring toFigure 7, thespring 510 ofFigure 5 can be cut from aflat sheet 770 of metal material, such as, for example, stainless steel. Other aspects of thespring 510 can be formed from asheet 770 of another material, such as spring steel, aluminium, plastic, nitinol, or any other suitable material in sheet form. A pattern of thespring 510, such as thewave pattern 772 depicted, can be etched, stamped, or otherwise cut into thesheet 770, and anyexcess sheet material 774 can be removed.
In another aspect, not part of the present invention, thespring 110 can be formed from a wire (not shown) and worked into the wave-pattern shape of the wave-pattern spring 510. For example, the wire can be hot worked or cold worked into the wave-pattern shape. In other aspects, the wire can be worked into another desired spring shape. Furthermore, in example aspects, after working the wire into the desired shape, thespring 110 can be heat treated to allow thespring 110 to retain a spring temper.
Figure 8 illustrates thespring 510 in the unrolledconfiguration 442 with theexcess sheet material 774 removed. As shown, thespring 510 can define thefirst end 444 and the oppositesecond end 446. Thefirst end 444 can define a pair of L-shapedhooks 880 extending downwardly therefrom, relative to the orientation shown. Thesecond end 446 can define a pair of mating L-shaped hooks 882 extending upwardly therefrom, relative to the orientation shown. Thespring 510 can be rolled to define thetubular structure 511 shown inFigure 5, and thehooks 880 at thefirst end 444 can engage the mating hooks 882 at thesecond end 446 to retain thespring 510 in the rolledconfiguration 140.
Figure 9 illustrates another aspect, not part of the present invention, of thespring 110. In this aspect, thespring 110 can be awave pattern spring 910 substantially similar to thespring 510 ofFigures 5-8; however, thespring 910 can define a length L₂ greater than a length L₁ (shown inFigure 8) of thespring 510. For example, in one aspect, thespring 510 can define a length L₁ of between about 5 inches and 7 inches, and in other aspects, thespring 510 can define a length L₁ of about 6 inches. Furthermore, in one aspect, thespring 910 can define a length L₂ of between about 7 inches and 9 inches, and in other aspects, thespring 910 can define a length L₂ of about 8 inches. In other aspects, the lengths L₁, L₂ of the springs 510,910, respectively, can be greater or less than the example aspects described, and this disclosure should not be viewed as limiting.
Figure 10 illustrates an exploded view of another aspect, not part of the present invention, of thestent 100. As shown, thestent 100 can comprise thespring 110 and thesealing layer 130. In the present aspect, thespring 110 can be atorsion spring 1010. In the compressed configuration, a twisting force can be applied to thetorsion spring 1010, such that a diameter of thetorsion spring 1010 and the overall stent diameter can be reduced. In the expanded configuration, the twisting force can be removed and thetorsion spring 1010 can spring radially outward, biasing thesealing layer 130 radially outward against theinner wall 552 of the pipe 550 (shown inFigure 5).

Claims

A stent (100) for repairing a leak in a pipe carrying water, gas, and/or oil, the stent (100) comprising:
a spring (110) defining a tubular mesh structure, the spring (110) defining an outer surface and an inner surface, the inner surface defining a void (120); and
a seal (130) wrapped around the outer surface of the spring (110);
the stent (100) configurable in a compressed orientation, wherein the spring (110) is compressed, and an expanded orientation, wherein the spring (110) is expanded, the spring (110) biasing the stent to the expanded orientation.
The stent (100) of claim 1, wherein a compression force is applied to the stent (100) in the compressed orientation by a compression mechanism, and wherein the compression mechanism is selected from one of a compression sleeve, a cable, a hose clamp, and a dissolvable wire.
The stent (100) of claim 1, wherein a diameter of the stent (100) in the compressed orientation is smaller than a diameter of the stent in the expanded orientation.
The stent (100) of claim 1, wherein the spring (110) comprises at least one of sheet metal, stainless steel, spring steel, nitinol, aluminium, nylon, polyoxymethylene, and polyvinyl chloride, and wherein the seal comprises a flexible material, the flexible material comprising at least one of foam, natural rubber, synthetic rubber, epoxy, a resin-soaked cloth, and silicone.
The stent (100) of claim 1, wherein the stent defines a cylindrical structure in the expanded orientation, the cylindrical structure defining a pair of opposing open ends.
The stent (100) of claim 1, wherein the spring defines a pattern, wherein the pattern is a mesh pattern.
The stent (100) of claim 1, wherein the seal (130) is attached to the spring by a fastener.
The stent (100) of claim 1, wherein the spring (110) is configurable in an unrolled configuration and a rolled configuration, the spring (110) defining a first end and a second end, the first end attached to the second end in the rolled configuration.
A pipe assembly comprising:
a pipe (550) comprising an inner wall, the inner wall defining a first void; and
a stent (100) according to any of claims 1 to 8.
The pipe assembly of claim 9, wherein the inner wall defines an inner diameter of the pipe (550) and the seal (130) defines an outer diameter of the stent (100), and wherein the outer diameter of the stent (100) in the compressed orientation is smaller than the inner diameter of the pipe (550).
The pipe assembly of claim 10, wherein the outer diameter of the stent (100) in the expanded orientation is greater than or equal to the inner diameter of the pipe (550).
The pipe assembly of claim 9, wherein the spring (110) defines an inner spring surface, the inner spring surface defining a second void, the second void concentric to the first void.
A method for repairing a pipe (550) comprising:
compressing a stent (100) according to any of claims 1 to 8;
inserting the stent (100) into the pipe (550);
positioning the stent (100) proximate to a leak in the pipe (550); and
expanding the stent (100) to cover the leak with the seal (130).
The method of claim 13, wherein compressing the stent (100) comprises applying a compression force to the stent (100) with a compression mechanism, and wherein expanding the stent (100) comprises one of removing and reducing the compression force.
The method of claim 13, wherein expanding the stent (100) comprises biasing the seal (130) against the leak with the spring (110).